Multi-Stage Supply Chain Management System With Dynamic Order Placement

ABSTRACT

A global supply chain management system in an environment of multiple suppliers forming supply chains for one or more buyers connected over the Internet. The system includes a global processor with logic that maps “local” supply information for each buyer and each supplier, represented in one or more property tables having master information correlated to local information for each buyer and each supplier. The system manages processes from an input of lots to an output through supplier stages where clients each use fragmented different local information. A correlation means uses base lot indicators, one for each of the lots in common for all of said stages and executes supply chain management functions for tracking lots through the supplier stages and for dynamic creation of sets of purchase orders among groups of suppliers for processing the same lot through the supply chain.

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BACKGROUND OF THE INVENTION

The present invention relates to internet commerce and particularly tomethods and apparatus that enable efficient management of procurementtransactions between buyers and suppliers in a supply chain thatincludes outsourcing with multiple suppliers.

Today, buyers and suppliers operate in a fast changing globalenvironment where quantities needed, pricing, technical specificationsand other supply parameters are frequently changing. The supply chainfor procurement of goods and services requires economies of scale,market pricing and rapid delivery. The management of the process ofprocuring goods and services is known as “supply chain management”.

Supply chain management is affected, for example, by the globalizationof businesses, the proliferation of product and service variety, theincreasing complexity of supply networks, and the shortening of productlife cycles. Market conditions are susceptible to rapid demandfluctuation, inventory buildup, price competition, and frequentspecification changes. The supply chain for any particular company maybe primarily internal supply. However, outsourcing is often used as analternative to internal supply. By way of example, outsourcing is usedto reduce costs, control inventories and respond to rapid demandchanges. Outsourcing increasingly is involving more and more suppliersand supply chains are growing more complex.

In fast changing markets, buyers require “current” and at times“real-time” quotes and other information from suppliers that specify,among other things, accurate quantities, prices and delivery times. Theability to rapidly exchange information among buyers and suppliers isparamount to efficient supply chain management, particularly in anoutsourcing environment.

The Internet is an efficient electronic link among buyers and suppliersfor exchange of supply chain information. The Internet operates withopen standards and permits easy, universal and secure informationexchange. Many roles exist for the Internet in commerce and some ofthese roles have been described as “e-business”, “e-commerce”, and“internet commerce”. For purposes of the present specification, the term“internet commerce” (or “i-commerce”) is used to represent the role ofthe Internet in supply chain management.

“Internet commerce” enables companies, among other things, to realizegreater W: efficiency, have better asset utilization, have faster timesto market, reduce order fulfillment times, enhance customer services andpenetrate new markets. The Internet provides an enormous capability fordistribution of “current” information that is useful and necessary forimproved supply chain management. “Current” information often must beinformation available on a “real-time” or near “real time” basis. TheInternet makes it possible to communicate “current” information abouttechnology changes, availability of goods and services, up-to-dateprices for goods and services and other information needed to manage asupply chain. When outsourcing is employed in the supply a chain, thevisibility into the current status of the supply chain is more difficultand requires new and improved methods for insuring that complete,accurate and timely information is available. In the absence of suchcurrent information, the ability to react in a timely way to exceptions,abnormal events and other matters may be lost or delayed. When the timefor taking action is not recognized or is delayed, supply chainmanagement suffers and ultimately the cost of goods and servicesincreases.

Although internet commerce simplifies many aspects of procurement,difficulties still exist and improvements are needed. One difficultyresults because large numbers of suppliers and buyers are attached tothe market place and each participant, whether buyer or supplier, tendsto use different parameters, terminology, terms, conditions and otherinformation unique to the particular participant. These differencesamong participants result in an information exchange problem.

The information exchange problem is particularly acute, for example, inthe outsourcing semiconductor manufacturing industry because goods andservices procured from one supplier are frequently further processed byother suppliers in subsequent downstream stages. In order to haveefficient and economical supply chain management, the interrelationshipamong each buyer and the upstream and down stream suppliers requires anexchange of “current” information that permits real-time visibility intothe status of the supply chain, fast identification of abnormal eventsand other information that permits exception management.

One difficulty that frustrates the good visibility necessary for supplychain management is the proliferation of different terminology andspecifications used by each participant in the supply chain. While anydominating buyer (and potentially any dominating supplier) can demandconformance with its way of doing business for its own business, thesemiconductor C, manufacturing industry as a whole remains widelyfragmented without much progress toward standardization. Furthermore,this fragmentation is increasing rather than decreasing so that problemsare bound to exist for many years to come. The fragmentation exists, ofcourse, in many other industries.

Cooperative attempts have been made toward standardization in someindustries. In the electronics component industry, the RosettaNet hasthe intent of providing industry wide standardization across theelectronic components trading network. Some attempts have been made tostandardize the semiconductor manufacturing industry. Notwithstandingthese attempts, the semiconductor manufacturing industry remainsfragmented and neither the RosettaNet nor any other standard has becomewidely adopted.

Accordingly, there is a great demand for improved supply chainmanagement methods and apparatus that will operate efficiently infragmented markets.

SUMMARY

The present invention is a global supply chain management system in anenvironment of multiple suppliers forming supply chains for one or morebuyers connected over the Internet. The system includes a globalprocessor with logic that maps “local” supply information for each buyerand each supplier, represented in one or more property tables havingmaster information correlated to local information for each buyer andeach supplier. The system manages processes from an input of lots to anoutput through supplier stages where clients each use fragmenteddifferent local information. A correlation means uses base lotindicators, one for each of the lots, in common for all of said stagesand executes supply chain management functions for tracking lots throughthe supplier stages and for dynamic creation of sets of purchase ordersamong groups of suppliers for processing the same lot through the supplychain.

The environment is fragmented, that is, the industry as a whole has notadopted any common set of standard terminology. In a fragmentedindustry, each instance of local supply information for any client(buyer or supplier) can be and usually is different from the localsupply information for any other client (buyer or supplier). Theembodiments of the present invention map supply information from and tothe master internal property information to and from fragmented outputlocal information according to the local property correlation for eachbuyer and each supplier. Notwithstanding the fragmentation among buyersand suppliers, the global supply chain management system functions toimplement global supply chain management using “current” supply chaininformation supplied over the Internet using the fragmented local supplyinformation used by the buyer or supplier.

To insure that the supply information is accurate, the global processorexecutes data integrity processes to improve the reliability of thesupply information. The data integrity processes include data checkingand data cleansing so that mapped supply information through errordetection and correction becomes more accurate than the originalfragmented raw data. Data integrity processes are performed, forexample, for data consistency within a record, data consistency within areport, data consistency across different reports from a particularsupplier, data consistency between suppliers' and buyers' data and dataconsistency among suppliers.

Based upon a continuously updated data base having “current” supplyinformation, the global processor provides reports for numerous datatypes including work-in-progress (WIP) reports, activity-basedtransaction reports (TR) that are created on a daily or other basis(including detail for each buyer and supplier stage), order reports,shipment reports and invoice reports. The terminology for the variousreports and the items reported upon have no standard definitions. Forexample, Orders are known by different names including purchase orders(PO) that logically are for goods and work orders (WO) that logicallyare for services. However, common practice in many industries uses theterm Purchase Order generically for any type of order whether for goodsor services. These reports are all conveniently distributed over theInternet in a format and with the terminology selected by each client,whether the client is a buyer or a supplier.

With access to “current” supply information for multiple suppliers andwith mapping capability among fragmented local property tables ofmultiple suppliers and buyers, the global processor enables the Internetplacement of purchase orders and work orders (POs and WOs) that can beaccompanied by detailed specifications using electronic attachments.

With access to “current” supply information for multiple suppliers andwith mapping capability among fragmented local property tables ofmultiple suppliers and buyers, the global processor enables globalplanning from input to output of the supply chain. In the semiconductormanufacturing supply chain, the planning extends from Wafer (front end,upstream) planning to package/test (back end, down stream) planning.

The supply chain management system is able to provide lot trackingreports, actual cost lot detail reports, wafer rolling output reports,finished goods rolling output reports, work in progress inventoryreports and other reports useful for supply chain management.

The supply chain management system employs planning based upon upstreamvisibility in the supply chain. Such capabilities are particularlyuseful in outsourcing to suppliers in a semiconductor supply chain. Inthe semiconductor IC-design outsourcing industry, the buyer (IC-designhouse) deals with multiple suppliers that provide various outsourcingfunctions at different supplier stages. The buyer places a separateorder (Purchase Order) with each supplier. Although the Purchase Ordersare separate between a buyer and each supplier, each supplier depends onthe previous supplier (upstream supplier) in the supply chain.

In the semiconductor manufacturing industry in order to procure finishedgoods (for example a finished semicondcutor chip), a buyer first orderswafers from a Fab supplier (foundry); once the work at the Fab supplieris finished, the buyer orders sorting from a Wafer Sort supplier; afterthe Wafer Sort work is finished, the buyer orders Assembly from anAssembly supplier; and finally, the buyer orders Final Test from a FinalTest supplier. The supply chain management system is able to performgroup order generation for groups of dependent suppliers (such as Fab,Wafer Sort, Assembly and Final Test suppliers) in the supply chain.

The supply chain management system performs alert processes based uponalert conditions for specific events/reports/process of the supplychain. Alert reports are accessible to clients through i-commerceonscreen operations or through other methods of communication.Typically, alert conditions are communicated daily (or more frequentlyif desired) in the form of event generation and alert messages.

The input to the supply chain can take many forms and is a function ofthe particular industry. The input can be raw materials, groups ofcomponents or “lots” of any kind. In the semiconductor manufacturingindustry, frequently “lots” are “wafer lots” or “die lots”.

Lot Tracking is implemented by logic in the global processor to storedetailed information related to a lot in the supply chain. The lottracking information is categorized into two major parts, namely, staticdata where the data are fixed during the manufacturing processes anddynamic data where the data can be changed during the manufacturingprocesses. For example, the static data includes Date Code, Lot No,Order Date, Order Qty, Part No, Production Order No, PO No, Routing,Sup, and Unit Price. For example, the dynamic data includes two mainparts, namely, Date Information, {Completed Date, Hold Date, ReceivedDate, Ship Date, Start Date} and Quantity Information (Completed Qty,Downgrade Qty, Goodpart Qty, Hold Qty, Received Qty, Returned Qty,Scrappart Qty, Ship Qty, Start Qty}.

Lot tracking stores the genealogy of a lot in order to track and recallthe lot history quickly. This tracking is done by storing theparent-child relationship for lots. For flexible in loading the lottracking data, work-in-progress (WIP) reports and activity-basedtransaction reports (TR) are used.

Lot tracking is unique in the sense that a robust and consistent dataset for the production and finance related information of a fragmentedsupply chain is maintained in one central place. The maintenance of suchinformation permits performance checking, such as cycle time, yieldanalysis and cost reporting on a lot basis down to each stage of thesupply chain.

The foregoing and other objects, features and advantages of theinvention will be apparent from the following detailed description inconjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a plurality of supply chain management systems organizedin part on an individual buyer basis and in an environment of multiplebuyers and multiple suppliers forming a supply chain and depicts aglobal supply chain management system for the multiple buyers andmultiple suppliers.

FIG. 2 depicts further details of the global supply chain managementsystem of FIG. 1 with a multi-stage, multi-lot processor for multiplebuyers and multiple suppliers.

FIG. 3 depicts details of the supply chain management system of FIG. 1and FIG. 2 with details for typical stages for processing.

FIG. 4 depicts details of a single one of the buyers and multiplesuppliers for the multistage, multi-lot processing within the supplychain management system of FIG. 1 and FIG. 2.

FIG. 5 depicts one example of a purchase order set for a lot in the FIG.4 system.

FIG. 6 depicts another example of a purchase order set for a lot in theFIG. 4 system.

FIG. 7 depicts another example of a purchase order set for a lot in theFIG. 4 system.

FIG. 8 depicts details of a multiple ones of the buyers and multiplesuppliers for the multistage, multi-lot processing within the supplychain management system of FIG. 1.

FIG. 9 depicts a hardware block diagram of a computer system network forthe supply chain management system of FIG. 1.

FIG. 10 depicts a software block diagram for the supply chain managementsystem of FIG. 1.

FIG. 11 depicts a correlation processor for correlating input and outputinformation among clients including mapping and data integrityprocessing in the FIG. 9 and FIG. 10 systems for supply chainmanagement.

FIG. 12 depicts one example all of a multiple supplier branch in asupply chain transaction.

FIG. 13 depicts a cross supplier error checking in the example of FIG.12.

FIG. 14 depicts one example of a lot tracking report.

FIG. 15 depicts a cross supplier lot tracking example 1.

FIG. 16 depicts a cross supplier lot tracking example 2.

FIG. 17 depicts an actual cost—lot detail report.

FIG. 18 depicts the purchase order logic flow for creation andacceptance of blanket purchase orders and purchase orders.

FIG. 19 depicts an example of Final Test purchase order.

FIG. 20 depicts an example of an attachment that appears as a thumbnailimage in the Final Test purchase order of FIG. 19.

FIG. 21 depicts an example of a wafer rolling output report.

FIG. 22 depicts an example of a finished goods rolling output reportwith package planning.

FIG. 23 depicts an example of a work in progress inventory report.

DETAILED DESCRIPTION

FIG. 1 depicts a plurality of supply chain management systems 2-1, 2-2,. . . , 2-M organized on an individual buyer (B) basis for the buyers3-1, 3-2, . . . , 3-B in an environment also including multiplesuppliers 7-1, 7-2, . . . , 7-S. FIG. 1 also depicts a supply chainmanagement system 1 serving all the multiple buyers 3-1, 3-2, . . . ,3-B and multiple suppliers 7-1, 7-2, . . . , 7-S. The multiple buyersand multiple suppliers of FIG. 1 are connected over the internet andhence are able to exchange supply information rapidly and essentially inreal time.

In FIG. 1, the local supply chain for each buyer includes supply stages4 that typically include internal supply 5, that is, supply from thebuyer's own organization, and outsourced supply 6, that is, supply fromexternal suppliers 7-1, 7-2, . . . , 7-S. Specifically, the buyers 3-1,3-2, . . . , 3-B have the supply stages 4-1, 4-2, . . . , 4-B, each inturn having the internal supply 5-1, 5-2, . . . , 5-SS and the externalsupply 6-1, 6-2, . . . , 6-SS, respectively.

Each of the local supply chain management systems 2-1, 2-2, . . . , 2-Mare maintained, for example, by the individual buyers 3-1, 3-2, . . . ,3-B and they are typically characterized as having their ownterminology, specifications and other supply chain parameters. In FIG.1, the suppliers and buyers as a whole are widely fragmented withoutmuch standardization. FIG. 1, therefore, as it encompasses local supplychain management systems 2-1, 2-2, . . . , 2-M is representative of thesemiconductor manufacturing industry.

Additionally, in FIG. 1, a global supply chain management system 1 isdesigned to overcome the local fragmentation and efficiently serve allthe multiple buyers 3-1, 3-2, . . . , 3-B and multiple suppliers 7-1,7-2, . . . , 7-S. The supply chain management system 1 includes a aglobal processor 8 that uses network communications such as the Internetfor overcoming the fragmentation of local supply chain managementsystems 2-1, 2-2, . . . , 2-M and for providing integrated supply chainmanagement. FIG. 2 depicts a supply chain management system operating inan environment of one or more buyers, B, including buyers B₀, B₁, . . ., B_(B) multiple suppliers, S, including suppliers S₀, S₁, . . . , S_(S)in a supply chain. The buyers and suppliers are connected to aMulti-stage, Multi-Lot Processor for Multiple Buyers (B) and MultipleSuppliers (S) where the supply chain includes inputs I₀, I₁, . . . ,I_(i), . . . , I_(I) to the supply chain and outputs O₀, O₁, . . . ,O_(o), . . . , O_(O) from the supply chain. The inputs are introduced toand the outputs are derived from Multiple Processing Stages (P) withMultiple Transactions (T) per Stage. The stages include [P_(0,0),P_(0,1), . . . , P_(0,N]); [P_(1,0), . . . ]; [ . . . , P_(m,n), . . .]; [P_(M,0), . . . , P_(M,N)]. Each stage such as a typical stageP_(m,n) includes up to T transactions such as T₀, T₁, . . . , T_(t),T_(T).

FIG. 3 depicts details of the supply chain management system of FIG. 2and details typical stages for processing. The one or more buyers, B,including B₀, B₁, . . . , B_(b), . . . , B_(B), and the multiplesuppliers, S, including S₀, S₁, . . . S_(s), . . . , S_(S) are in thesupply chain. Stages P_(m,n) and P_(m,n+1) are typical of the manystages [P_(0,0), P_(0,1), . . . , P_(0,N)]; [P_(1,0), . . . ]; [ . . . ,P_(m,n), . . . ]; [P_(M,0), . . . , P_(M,N)] of FIG. 2. In particular,stage P_(m,n) includes up to T transactions such as T₀, T₁, . . . ,T_(T). By way of example, stage P_(m,n) includes transactions (T₀),(T₁), (T₂), (T₃), (T₄), (T₅), . . . , (T_(T)) which are, for example,ORDER, WIP, YIELD, SHIPMENT, RECEIVE, WAREHOUSE, . . . , PAYMENT. Manyother transactions are possible, of course.

In FIG. 3, the stage P_(m,n) is in the supply chain with B_(b) as thebuyer and S_(s) as the supplier. By way of another example, the stageP_(m,n+1) is also in the supply chain with B_(b) as the buyer and S_(s)as the supplier. The stage P_(m,n+1) may include the transactions (T₀),(T₁), (T₂), (T₃), (T₄), (T₅), . . . , (T_(T)) which are for P_(m,n)ORDER, WIP, YIELD, SHIPMENT, RECEIVE, WAREHOUSE or stage P_(m,n+1) mayhave a different set of transactions.

FIG. 4 depicts details of a single one of the buyers and multiplesuppliers for the multistage, multi-lot processing within the supplychain management system of FIG. 2. FIG. 4 depicts a supply chainmanagement system operating in an environment of one buyer, B_(b) andmultiple suppliers, S, including S₀, S₁, S₂, S₃, S₄, S₅, . . . , S_(S)in a supply chain. The buyers and suppliers are connected to aMulti-stage, Multi-Lot Processor for Multiple Buyers (B) and MultipleSuppliers (S) where the supply chain includes inputs I₀, I₁, I₂, . . . ,I_(I) to the supply chain and outputs O₁, O₁, O₂, . . . , O_(O) from thesupply chain. The inputs are introduced to and the outputs are derivedfrom Multiple Processing Stages (P) with Multiple Transactions (T) perStage. The stages include [P_(0,0), P_(0,1), P_(0,2), P_(0,3)];[P_(1,0), P_(1,0), P_(1,2), P_(1,3]); . . . ; [P_(x,0), P_(x,1),P_(x,2), P_(x,3]); . . . ; [P_(M,0), . . . , P_(M,3)]. Each of thosestages includes a set of up to T transactions such as T₀, T₁, . . . ,T_(t), . . . , T_(T) like those described in connection with FIG. 2.

In FIG. 4, buyer, B_(b) initiates operation of the supply chain inconnection with a purchase by authorizing inputs I₁ and I₂. The I₁input, such as a semiconductor lot (wafer lot or die lot), to the supplychain progresses through a first sequence of stages [P_(0,0), P_(x,1),P_(1,2), P_(1,3)] to the output O₁. The supplier for the stage P_(0,0)stage is S₀, the supplier for the stage P_(x,1) stage is S₂, thesupplier for the stage P_(1,2) stage is S₃ and the supplier for thestages P_(1,3) stage is S₅. Similarly, the I₂ input, such as asemiconductor lot, to the supply chain progresses through a secondsequence of stages [P_(0,0), P_(0,1) P_(x,2), P_(x,3)] to the output O₂.The supplier for the stage P_(0,0) stage is S₀, the supplier for thestage P_(0,1) stage is S₁, the supplier for the stage P_(x,2) stage isS₄ and the supplier for the stages P_(x,3) stage is S_(S). FIG. 4depicts details of a single one of the buyers and multiple suppliers forthe multistage, multi-lot processing within the supply chain managementsystem of FIG. 1.

FIG. 5 depicts one example of a purchase order set for multistageprocessing in the FIG. 4 system. In FIG. 5, buyer, B_(b), initiatesoperation of the supply chain in connection with a purchase byauthorizing input I₁. The input I₁ to the supply chain progressesthrough a sequence of stages [P_(0,0), P_(x,1), P_(1,2), P_(1,3)] toprovide the output O₁. The supplier for the stage P_(0,0) stage is S₀,the supplier for the stage P_(x,1) stage is S₂, the supplier for thestage P_(1,2) stage is S₃ and the supplier for the stages P_(1,3) stageis S₅. In order for the work to be performed through the stages[P_(0,0), P_(x,1), P_(1,2), P_(1,3)] of FIG. 5, orders authorizing andspecifying the terms and conditions associated with the work are agreedupon by the buyer, B_(b), and the suppliers S₀, S₂, S₃, and S₅. Theorders in FIG. 5 are designated P_(0,0)S₀, P_(x,1)S₂, P_(1,2)S₃ andP_(1,3)S₅. These orders are called “purchase orders” or “work orders”and apply to goods and services. In some industries, both goods andservices are involved but in other industries either goods or servicesalone are involved.

In a semiconductor manufacturing environment, both goods and servicesare involved. Typically, the I₁ input is a lot (wafer lot or die lot)and the processing stages are typically Fab, Wafer Sort, Assembly andFinal Test. Other stages are of course possible and include, forexample, Packaging (such as tape and real), Bumping and Marking. Theprocessing stages Fab, Wafer Sort, Assembly and Final Test are eachperformed by a supplier and typically the different suppliers S₀, S₂,S₃, and S₅. The work at each of the processing stages of Fab, WaferSort, Assembly and Final Test is authorized and controlled by thepurchase orders P_(0,0)S₀, P_(x,1)S₂, P_(1,2)S₃ and P_(1,3)S₅,respectively. The output from the stages [P_(0,0), P_(x,1), P_(1,2),P_(1,3)] are represented by [G_(0,0), G_(x,1), G_(1,2), O₁],respectively. In FIG. 5, the set of purchase orders [P_(0,0)S₀, P_(x,1),S₂, P_(1,2)S₃, P_(1,3)S₅] relate to interdependent work steps. Theoutput, O₁, is only obtained when all of the orders [P_(0,0)S₀,P_(x,1)S₂, P_(1,2)S₃, P_(1,3)S₅] have been executed according to theirterms and in sequence from the most upstream order P_(0,0)S₀ in turnthrough the orders P_(x,1)S₂, P_(1,2)S₃ to the most downstream orderP_(1,3)S₅. Furthermore, the downstream orders depend upon theperformance of the upstream orders. Typically, in the semiconductormanufacturing industry, the output at any stage is a variable, forexample, varying as to supply chain parameters such as quantity, qualityand delivery time. Accordingly, orders with downstream suppliers oftenneed to be conditioned upon the results of one or more upstreamsuppliers.

When information in a supply chain is not accurate and “current”, theentire supply chain can become inefficient, subject to distortion andunstable. One of the common distortion problems is escalatingover-requirement forecasts that tend to greatly exceed market demand.Such escalation is sometimes referred to as a “bullwhip” effect. The“bullwhip” results when each supplier in the supply chain over statesactual demand. The over demand escalates as forecasts are propagateddownstream in the supply chain. Each downstream supplier amplifies theover-requirement of the previous stage.

In the FIG. 5 purchase order set, each of the suppliers receives“current” and accurate information from upstream suppliers through useof communications over the Internet. The “current” information helps toreduce supply chain escalation of over requirements.

FIG. 6 depicts another example of a purchase order set for multistageprocessing in the FIG. 4 system. In FIG. 6, buyer, B_(b), initiatesoperation of the supply chain in connection with a purchase byauthorizing input 12. The input 12 to the supply chain progressesthrough a sequence of stages [P_(0,0), P_(0,1), P_(x,2), P_(x,3)] toprovide the output O₂. The supplier for the stage P_(0,0) stage is S₀,the supplier for the stage P_(0,1) stage is S₁, the supplier for thestage P_(x,2) stage is S₄ and the supplier for the stages P_(x,3) stageis S_(S). In order for the work to be performed through the stages[P_(0,0), P_(0,1), P_(x,2), P_(x,3)] of FIG. 6, orders authorizing andspecifying the terms and conditions associated with the work are agreedupon by the buyer, B_(b), and the suppliers S₀, S₁, S₄, and S_(S). Theorders in FIG. 6 are designated P_(0,0)S₀, P_(x,1)S₂, P_(1,2)S₃ andP_(1,3)S₅.

In a semiconductor manufacturing environment, the I₂ input is a waferlot and the processing stages are typically Fab, Wafer Sort, Assemblyand Final Test each performed by a supplier and typically the differentsuppliers S₀, S₁, S₄, and S_(S), respectively. The work at each of theprocessing stages of Fab, Wafer Sort, Assembly and Final Test isauthorized and controlled by the orders P_(0,0)S₀, P_(0,1)S₁, P_(x,2)S₄and P_(x,3)S_(S), respectively. The output from the stages [P_(0,0),P_(0,1), P_(x,2), P_(x,3)] are represented by [G_(0,0), G_(0,1),G_(x,2), O₂], respectively. In FIG. 6, the set of purchase orders[P_(0,0)S₀, P_(0,1)S₁, P_(x,2)S₄, P_(x,3)S_(S)] relate to interdependentwork steps. The output, O₂, is only obtained when all of the orders[P_(0,0)S₀, P_(0,1)S₁, P_(x,2)S₄, P_(x,3)S_(S)] have been executedaccording to their terms and in the sequence from the most upstreamorder P_(0,0)S₀ in turn through the orders P_(0,1)S₁, P_(x,2)S₄ to themost downstream order P_(x,3)S_(S).

In the FIG. 6 purchase order set, each of the suppliers receives“current” and accurate information from upstream suppliers through useof communications over the Internet. The “current” information helps toreduce supply chain escalation of over requirements.

FIG. 7 depicts another example of a purchase order set for multistageprocessing in the FIG. 4 system. In FIG. 7, buyer, B_(b), initiatesoperation of the supply chain in connection with a purchase byauthorizing input I₃. The input I₃ to the supply chain progressesthrough a sequence of stages commencing with a stage P_(0,0) andthereafter split into two sequences, namely, [P_(x,1), P_(1,2), P_(1,3)]to provide the output O₃ and [P_(x+1,1), P_(0,2), P_(0,3)] to providethe output O₄. The supplier for the stage P_(0,0) stage is S₀, thesupplier for the stage P_(x,1) stage is S₂, the supplier for the stageP_(1,2) stage is S₃ and the supplier for the stages P_(1,3) stage is S₅and the supplier for the stage P_(x+1,1) stage is S₆, the supplier forthe stage P_(0,2) stage is S₇ and the supplier for the stages P_(0,3)stage is S₈. In order for the work to be performed through the stageP_(0,0) an order authorizing and specifying the terms and conditionsassociated with the work are agreed upon by the buyer, B_(b), and thesupplier S₀. In order for the work to be performed through the stages[P_(x,1), P_(1,2), P_(1,3)] of FIG. 7, orders authorizing and specifyingthe terms and conditions associated with the work are agreed upon by thebuyer, B_(b), and the suppliers S₂, S₃ and S₅. In order for the work tobe performed through the stages [P_(x+1,1), P_(0,2), P_(0,3)] of FIG. 7,orders authorizing and specifying the terms and conditions associatedwith the work are agreed upon by the buyer, B_(b), and the suppliers S₆,S₇ and S₈. The orders in FIG. 7 are designated [PO_(0,0)S₀],[PO_(x,1)S₂, PO_(1,2)S₃, PO_(1,3)S₅] and [PO_(X+1,1)S₆, PO_(0,2)S₇,PO_(0,3)S₈].

In a semiconductor manufacturing environment, the I₃ input is a waferlot and the processing stages are typically Fab, Wafer Sort, Assemblyand Final Test each performed by a supplier and typically the differentsuppliers [S₀], [S₂ and S₆], [S₃ and S₇] and [S₅ and S₈], respectively.The work at each of the processing stages of Fab, Wafer Sort, Assemblyand Final Test is authorized and controlled by the orders [PO_(0,0)S₀],[PO_(x,1)S₂, PO_(1,2)S₃, PO_(1,3)S₅] and [PO_(x+1,1)S₆, PO_(0,2)S₇,PO_(0,3)S₈]. The output from the stage P_(0,0) is split and isrepresented by [₁G_(0,0) and ₂G_(0,0)]. The outputs from the stages[P_(x,1), P_(x,2), P_(x,3)] are represented by [G_(x,1), G_(1,2), O₃],respectively. The outputs from the stages [P_(x+1,1), P_(0,2), P_(0,3)]are represented by [G_(x+1), G_(0,2), O₄], respectively.

In FIG. 7, the sets of purchase orders [P_(0,0)S₀], [PO_(x,1)S₂,PO_(1,2)S₃, PO_(1,3)S₅] and [PO_(x+1,1)S₆, PO_(0,2)S₇, PO_(0,3)S₈]relate to interdependent work steps. The output, O₃, is only obtainedwhen all of the orders [PO_(0,0)S₀] and [PO_(x,1)S₂, PO_(1,2)S₃,PO_(1,3)S₅] have been executed according to their terms and in thesequence from the most upstream order to the most downstream order. Theoutput, O₄, is only obtained when all of the orders [PO_(0,0)S₀] and[PO_(x+1,1)S₆, PO_(0,2)S₇, PO_(0,3)S₈] have been executed according totheir terms and in the sequence from the most upstream order to the mostdownstream order. Further each of the subset order sequences[PO_(x,1)S₂, PO_(1,2)S₃, PO_(1,3)S₅] and [PO_(x+1,1)S₆, PO_(0,2)S₇,PO_(0,3)S₈] are interdependent in that they both drive from the parentorder [PO_(0,0)S₀].

In the FIG. 7 purchase order set, each of the suppliers receives“current” and accurate information from upstream suppliers through useof communications over the Internet. The “current” information helps toreduce supply chain escalation of over requirements. The FIG. 7sequences indicate the complexity that arises among suppliers in amultistage supply chain typical of outsourcing in the semiconductormanufacturing industry when only a single buyer, B_(b) is considered.

FIG. 8 depicts a supply chain management system 1 operating in anenvironment of multiple buyers (B) 3 including buyers (B₀, B₁, . . . ,B_(b), . . . , B_(B)) 3-1, 3-2, . . . 3-b, . . . , 3-B and multiplesuppliers (S) 7 including suppliers (S₀, S₁, . . . , S_(S)) 7-1, 7-2, .. . , 7S in a supply chain. The buyers 3 and suppliers 7 are connectedto a multi-stage, multi-lot processor 8′ that is one embodiment of theglobal processor 8 of FIG. 1. In FIG. 8, the buyer B_(b) is typical ofall the buyers B₀, B₁, . . . , B_(b), B_(B) and buyer B_(b) placesorders and receives goods and services from a multistage supply chainP{B_(b)} 4-b. The multistage supply chain P{B_(b)} is like any of themultistage supply chains described in connection with FIG. 1 throughFIG. 7. For the semiconductor manufacturing industry, the multistagesupply chain P {B_(b)} includes a plurality of stages P_(bx) organizedfunctionally, for example, into Fab, Wafer Sort, Assembly and Final Teststages. The stages P_(bx) are like any of the stages described inconnection with FIG. 1 through FIG. 7. The single buyer B_(b) is typicaland more generally all the buyers B₀, B₁, . . . , B_(b), . . . , B_(B)are associated with multistage supply chains P{B₀}, P{B₁}, . . . ,P{B_(b)}, . . . , P{B_(B)}, respectively. The stages P_(bx) for anyparticular one of the supply chains P{B₀}, P{B₁}, . . . , P{B_(b)}, . .. , P{B_(B)} may be same as or different from the stages P_(bx) for anyother ones of the supply chains P{B₀}, P{B₁}, . . . , P{B_(b)}, . . . ,P{B_(B)}. FIG. 8 indicates the great complexity of the supply chainenvironment for multiple buyers and multiple suppliers common in manyindustries such as the semiconductor manufacturing industry.

FIG. 9 depicts a hardware block diagram of a computer system network forthe supply chain management system of FIG. 1. In FIG. 9, theCLIENT(BUYER/SUPPLIER) 91-1, the CLIENT(BUYER/SUPPLIER) 91-2 and theCLIENT(BUYER/SUPPLIER) 91-C connect over INTERNET 99 to MULTI-STAGE,MULTI-LOT PROCESSOR 8 and particularly to the SWITCH 92. The SWITCH 92functions to switch incoming and outgoing traffic between the LOADBALANCER 93-1 and the LOAD BALANCER 93-2. The LOAD BALANCER 93-1 and theLOAD BALANCER 93-2 connect between the SWITCH 94-1 and the SWITCH 94-2.The SWITCH 94-1 and the SWITCH 94-2 connect to the APPLICATION SERVER95-1 and the APPLICATION SERVER 95-2. The APPLICATION SERVER 95-1 andthe APPLICATION SERVER 95-2 execute programs for performing supply chainmanagement in the multiple buyer, multiple supplier environment. TheAPPLICATION SERVER 95-1 and the APPLICATION SERVER 95-2 connect throughDATA SERVER 96-1 and DATA SERVER 96-2 to the DISK ARRAY 97 whichincludes the disks MAIL 97-1, DATABASE 97-2 and LOG-IN 97-3. Theprocessor 8 of FIG. 9 includes two-way redundancy for providing highlyreliable and highly available supply chain management services to thebuyers and suppliers that are the clients in the network.

FIG. 10 depicts a software block diagram for the supply chain managementsystem of FIG. 1. In FIG. 9, the CLIENT (BUYER/SUPPLIER) 91-1, theCLIENT (BUYER/SUPPLIER) 91-2 and the CLIENT (BUYER/SUPPLIER) 91-Cconnect over INTERNET 99 to MULTI-STAGE, MULTI-LOT PROCESSOR 8 andparticularly to the SECURITY/SWITCH 92′. The SECURITY/SWITCH 92′functions to perform security checks on the internet traffic and toswitch incoming and outgoing traffic between the WEB 98-1 and theBUSINESS LOGIC 98-2 executing in the PROCESS SERVERS 95′. The WEB 98-1and the BUSINESS LOGIC 98-2 and the APPLICATION SERVER 95-2 connect tothe DATA SERVER 97′ which includes MAIL 97′-1, DATABASE 97′-2 and LOG-IN97-3 functions. The WEB 98-1 process functions are primarily forreal-time interactive communications between the DATA SERVER 97′ andCLIENTs 91-1, 91-2, . . . , 91-C. The BUSINESS LOGIC 98-2 is primarilyfor performing the operations necessary for supply chain managementservices in the multiple buyer, multiple supplier environment. TheBUSINESS LOGIC 98-2 is logic means for accessing master information forexecuting supply chain management functions for the clients to providemanagement data.

FIG. 11 depicts a CORRELATION PROCESSOR 98′-2 for correlating input andoutput information among clients. The correlation is among the local andfragmented information that is different for each client. In theparticular embodiment of FIG. 11, the CORRELATION PROCESSOR 98′-2performs mapping and data integrity processing in connection with thesupply chain management. In FIG. 11, the CLIENTs 91-1, 91-2, . . . ,91-C connect over INTERNET 99 to the CORRELATION PROCESSOR 98′-2. TheCORRELATION PROCESSOR 98′-2 is part of the BUSINESS LOGIC 98-2 of FIG.10. The MESSAGE FILE CONNECTOR 88-1 functions using conventionalinternet protocols (httpRobot, ftpRobot, ftpServer) for incoming andoutgoing communications over the INTERNET 99. The FILE MONITOR 88-2detects the file format and makes conventional conversion to commaseparated values (for example, flat2csv, xls2csv). The CONVERTER 88-3converts the csv values to an xml format as an input to the INPUT MAPPER88-4. The INPUT MAPPER 88-4 functions to map the local property valuesinherent in the input data to master property values defined by thesupply chain management system. The INPUT MAPPER 88-4 accesses thePROPERTY TABLES in the DATABASE 97′-2 to do the mapping. After mapping,the mapped raw input data is converted in CONVERTER 88-5 from an xmlformat to a database format (xml TO db) and stored in the RAW DATA store88-7 ₁. The mapped raw input data is then processed in the DATAINTEGRITY UNIT 88-6 including the Data Checking unit 88-6 ₁ and the DataCleansing 88-6 ₂. The checked and cleaned processed input data is storedThe checked and cleaned raw data is processed in the PROCESS DATA UNIT98 and the processed data is stored in the PROCESSED DATA store 88-7 ₂.Any of the raw data in the RAW DATA store 88-7 ₁ or the processed datain the PROCESSED DATA store 88-7 ₂ can be communicated to the CLIENTs91-1, 91-2 and 91-C using the OUTPUT MAPPER 88-8 to map the output datato the form expected by the client. The OUTPUT MAPPER 88-8 functions tomap the master property information defined by the supply chainmanagement system to the local property information of the type and formused by clients as revealed in the input data from clients. The OUTPUTMAPPER 88-8 is an output mapping means for mapping management data tolocal data for clients. The OUTPUT MAPPER 88-8 accesses the PROPERTYTABLES in the DATABASE 97′-2 to do the mapping.

Different buyers, such as Fabless semiconductor companies, frequentlyrequire different information from their suppliers' daily or otherreports. Often suppliers can provide only one format for these reportsto all of their buyers due to the constraints in their computer systems.To bridge this information gap, the supply chain management system usesa database schema which provides a master property table holding a superset of information for all the clients (buyers and suppliers) using thesystem. When the buyers and suppliers send their records, reports andinquiries to the supply chain management system, the data are mappedinto the master database schema.

A client-specific property file is created to describe theclient-specific (“local”) data for each client. In one embodiment,MicroSoft BizTalk is used to generate a schema.biz and mapper.biz todefine the mapping between a client's local data and the master databaseschema. Then, a JAVA class, CSV2XML, is applied to convert these datareports from .DBF, .XLS or .CSV format into XML format files based onthe description in the corresponding local property files. The XML stylesheet file, .XSL, generated by the mapper.biz and the JAVA class, XML2DB, are used to convert the report data into the final format to beimported into the master table of the database.

The master table can be in any form including indexed files, linkedsub-tables, linked lists, among others. The following TABLE 1 is anexample of a master property table where the column “Field Name”represents the master table name and the column “Description” brieflydescribes the general use of the Field Name. TABLE 1 is representativeof a master table and is not intended to be exhaustive. Other fields areadded as the need arises.

TABLE 1 Copyright 2002 GetSilicon, Inc. Field Name Description 1 ActualCharge Charge for Units actually delivered as Final Product 2 Actual QtyQuantity of Units actually delivered as Final Product 3 Back Issue DieQty Back Issued Die Qty 4 Base Lot Indicator number derived from the lotgenealogy specification 5 Bin Physical bin location 6 Completed DateDate on which the manufacturing process completes 7 Completed Die QtyNumber of dies completed in the processing 8 Completed Qty Number ofUnits completed in the processing 9 Completed Wafer Qty Number of waferscompleted in the processing 10 Date Code Code to designate themanufacturing date of product 11 Description Description of processparameters 12 Device Type Type of device 13 Down Grade Qty Number ofUnits being downgraded to lower specs after production 14 Est AmountEstimated finished goods amount 15 Est_FG_Date Estimated finished goodsdate 16 Est_FG_Qty Estimated finished goods quantity 17 EstimateComplete Date Revised completion date based on the current processinformation 18 ETA Date Date of estimated time of arrival 19 Good UnitQty Number of good Units 20 Gross Ship Weight Gross weight as shipped 21Hold Date Date Hold starts 22 Hold Qty Number of Units on hold 23 I_NoIdentification number for product 24 Invoice Date Invoice created date25 Invoice No Invoice number 26 Lot No Number for Client derived fromBase Lot indicator 27 Net Shipping Weight Net weight as shipped 28 NotesSpecial instructions and details 29 Order Confirm Date Date orderconfirmed 30 Order Date Date on which the production order is issued 31Order Qty Quantity ordered 32 Order Req Date Date order requested 33Ordered Die Qty Ordered die qty 34 Ordered Wafer Qty Ordered wafer qty35 Part No Part number 36 PO No Purchase Order number 37 PO Rev NoRevolution of PO No 38 Process Name of detailed process used by Supplier39 Production Order No Number for production order 40 Received Date Dateon which Units are received 41 Received Die Qty Number of die receivedfor the manufacturing process 42 Received Qty Number of Units received43 Received Wafer Qty Number of wafer received for the manufacturingprocess 44 Return Code Code used to make a return 45 Return Order NoNumber used to make a return 45 Return Qty Number of Units returned 46Routing Name of stage, such as Fab, Wafer Sort, Assembly, Final Test 47Routing Status Status such as scheduled, started, active, hold,completed or shipped 48 Scrap Qty Number of Units being scraped 49Return Qty Number of Units being returned 50 Ship Cost Shipping cost 51Ship Date Date of current shipment 52 Ship Qty Unit quantity in thecurrent shipment 53 Ship Dimension Dimension of packed shipment 54 ShipLine No Number on shipping package 55 Ship To Destination client 56 ShipVia Carrier name 57 Shipping Notice No Number on shipping package 58Start Date Date on which the processing begins 59 Start Qty Number ofUnits when the processing starts 60 Sup Supplier name 61 Topmark Topmarkvisible on top of finished goods 62 Unit Unit type such as Wafer, Die 63Unit Price Unit price per Unit 64 Weighted Completed Date Weightedcompleted date, based on the quantity 65 Weighted Received Date Weightedreceived date, based on the quantity 66 Weighted Ship Date Weighted shipdate, based on the quantity 67 Weighted Start Date Weighted start date,based on the quantity 68 WIP Die Qty Number of dies that is active inthe production process 69 WIP Wafer Qty Number of wafers that is activein the production process 70 WO No Work Order No 71 WO Rev No Work OrderRev 72 Yield Output over input (in percent)

The following TABLE 2, TABLE 3 and TABLE 4 are examples of the masterproperty table and the corresponding local client information mapping.In TABLE 2, the column H “Field Name” represents the master tableinformation, the column “Buyer1” represents a buyer client local clientinformation of a buyer and the columns “Fab1”, “Wafer Sort1”,“Assembly1” and “Test1” represent local client information of foursuppliers representing different stages of semiconductor manufacturing.

In TABLE 3, the column “Field Name” represents the master tableinformation, the column “Buyer1” represents local client information ofa buyer and the columns “Wafer Sort1” and “Wafer Sort2” represent localclient information of two suppliers representing the same Wafer Sortstage of semiconductor manufacturing.

In TABLE 4, the column “Field Name” represents the master tableinformation, the column “Buyer1” represents a buyer client local clientinformation of a buyer and the columns “Assembly1”, “Assembly2” and“Assembly3” represent local client information of two suppliersrepresenting the same Assembly stage of semiconductor manufacturing.Certain ones of the fields in TABLE 1 derive directly from client fieldswhile others are derived as a result of processing.

Examples of derived fields include:

-   -   1) Base Lot. A derived number indicator used for tracking the        lot genealogy for a buyer through all suppliers.    -   2) In-Date. A derived date that is the earliest date associated        with any transaction at a client, for example, the earlier of        the Received Date and the Start Date.    -   3) Out-Date. The latest date associated with any transaction at        a client, for example, the later of the Complete Date and the        Ship Date.    -   4) The term Qty generally means quantities that have been        accumulated to show totals for one or more transactions or parts        of a transaction.    -   5) The term Weighted refers to dates weighted by quantity. For        example, for 100 pcs received on Jun. 5, 2002 0:0:0 and 200 pcs        received on Jun. 6, 2002 0:0:0, the Weighed Received Date is:        (date1*qty1+date2*qty2)/(qty1+qty2), the Weighted Received Date        is: Jun. 5, 2002 18:0:0.    -   6) Est_FG_Date. The estimated finished good date, the date which        the current material will be available as finished goods. The        Est_FG_Date is calculated based on the standard cycle time of        each stage (routing).    -   7) Est_FG_Qty. The estimated finish good quantity, the expected        quantity which the current material becomes the final finish        goods. The Est_FG_Qty is calculated based on the expected Yield        of each stage.    -   8) Yield. Determined as the ratio Output Qty/Input Qty.

The derived fields are only by way of example as any number ofadditional derived fields may be added as the need arises.

TABLE 2 # Field Name Buyer1 Fab1 Wafer Sort1 Assembly1 Test1 1 ShippingNotice PackageNO Invoice Number Reference_No Packing No Reference No No2 PO No Customer PO 3 PO Rev No 4 WO No Work Order No Work Order WONumber Po No No 5 WO Rev No Work Order Rev 6 Order Line No Order Line No7 Device Type Device 8 Part No Part Num Part No. Part Num Part No 9 I_NoI_No Customer Product No Device 10 Bin BIN BIN 11 Lot No CM Lot No Fab1Lot ID Lot No. Lot No Lot No 12 Description 13 Order Date 14 Order Qty15 Order Req Date 16 Order Confirm Date 17 UM 18 Ship Line No Package NOItem N 19 Ship Date PACKAGE Date Date Date Date 20 ETA Date 21 ShipWafer Qty Qty Ship Qty Wafer QTY Qty1 Shipping QTY 22 Ship Die Qty GoodDie Qty QTY Qty2 23 Ship To Ship To Ship to To Location 24 Ship Via VIAvia 25 Gross Ship Weight G.W 26 Net Shipping N.W Weight 27 ShipDimension Dimension 28 Ship Cost 29 Invoice Date invoice created dateinvoice date inv date 30 Invoice No Invoice No Invoice No Invoice NoInvoice No Invoice No 31 Notes 32 Date code Date Code 33 Return Order No34 Return Code

TABLE 3 # Field Name Buyer1 Wafer Sort1 Wafer Sort2 1 Shipping Notice NoPackage NO Reference_No F_SHIP_NO 2 PO No 3 PO Rev No 4 WO No Work OrderNo Work Order No F_RELEASE_NO 5 WO Rev No Work Order Rev 6 Order Line NoF_RELEASE_NO 7 Device Type Device Wafer 8 Part No Part Num Part No.F_CUST_PN 9 I_No I_NO 10 Bin BIN 11 Lot No CM Lot No Lot No.F_CUST_LOT_NO 12 Description 13 Order Date 14 Order Qty 15 Order ReqDate 16 Order Confirm Date 17 Unit 18 Ship Line No Package NO 19 ShipDate PACKAGE Date Date F_MODIFY_DATE 20 ETA Date 21 Ship Wafer Qty QtyWafer Shipping QTY F_PIECES 22 Ship Die Qty Good Die Qty F_GOOD_DIES 23Ship To F_SHIP_TO 24 Ship Via 25 Gross Ship Weight 26 Net ShippingWeight 27 Ship Dimension 28 Ship Cost 29 Invoice Date invoice createddate 30 Invoice No Invoice No Invoice No Invoice No 31 Notes 32 Datecode 33 Return Order No 34 Return Code

TABLE 4 # Field Name Assembly1 Assembly2 Assembly3 1 Shipping Notice NoPackage NO Packing No SHIPMENT NO 2 PO No 3 PO Rev No 4 WO No WO Num WONumber P.O.NUM 5 WO Rev No WO Rev Num 6 Order Line No Order Line No 7Device Type Device Type Device DEVICE 8 Part No Part No Part Num 9 I_No10 Bin 11 Lot No Lot No Lot No LOT NUM 12 Description 13 Order Date 14Order Qty Qty 15 Order Req Date 16 Order Confirm Date 17 Unit 18 ShipLine No Item 19 Ship Date ETA Date ETD 20 ETA Date ETD ETA 21 Ship WaferQty QTY 22 Ship Die Qty QTY QTY 23 Ship To Ship to Loc Ship to Location24 Ship Via VIA VIA FORWARDER 25 Gross Ship Weight G.W G.W WEIGHT 26 NetShipping Weight N.W N.W 27 Ship Dimension Dimension 28 Ship Cost 29Invoice Date 30 Invoice No Invoice Date invoice date 31 Notes Invoice NoInvoice No Invoice No 32 Date code 33 Return Order No 34 Return Code

One program for implementing the mapping described is presented in thefollowing TABLE 5.

TABLE 5 Copyright 2002 GetSilicon, Inc.  1 <xsl:stylesheetxmlns:xsl=‘http://www.w3.org/1999/XSL/Transform’xmlns:msxsl=‘urn:schemas-microsoft-com:xslt’  2 xmlns:var=‘urn:var’xmlns:user=‘urn:user’ exclude-result-prefixes=‘msxsl var user’version=‘1.0’>  3 <xsl:output method=‘xml’ encoding=‘UTF-8’ indent=‘yes’omit-xml-declaration=‘yes’ />  4 <xsl:template match=‘/’>  5 <xsl:apply-templates select=‘INSERT’/>  6 </xsl:template>  7<xsl:template match=‘INSERT’>  8 <INSERT>  9  <xsl:for-eachselect=‘ROWSET_shipHEADER’> 10   <ROWSET_SHIPHEADER> 11    <xsl:for-eachselect=‘ROW_shipHEADER’> 12     <ROW_SHIPHEADER> 13      <!-- Connectionfrom source node “ToID” to destination node “BUYER” --> 14     <BUYER><xsl:value-of select=‘ToID/text( )’/></BUYER> 15      <!--Connection from source node “FromID” to destination node “SUPPLIER” -->16      <SUPPLIER><xsl:value-of select=‘FromID/text( )’/></SUPPLIER> 17     <!-- Connection from source node “reportDate” to destination node“REPORTDATE” --> 18      <REPORTDATE><xsl:value-ofselect=‘reportDate/text( )’/></REPORTDATE> 19      <!-- Connection fromsource node “tDate” to destination node “TDATE” --> 20     <TDATE><xsl:value-of select=‘tDate/text( )’/></TDATE> 21      <!--Connection from source node “fileName” to destination node “FILENAME”--> 22      <FILENAME><xsl:value-of select=‘fileName/text()’/></FILENAME> 23      <!-- Connection from source node “fileSize” todestination node “FILESIZE” --> 24      <FILESIZE><xsl:value-ofselect=‘fileSize/text( )’/></FILESIZE> 25      <!-- Connection fromsource node “RecordSize” to destination node “RECORDSIZE” --> 26     <RECORDSIZE><xsl:value-of select=‘ancestor::*[2]/RecordSize/text()’/></RECORDSIZE> 27     <!-- Connection from source node“ROW_shipHEADER” to destination node “ROW_SHIPHEADER” --> 28    <xsl:value-of select=‘./text( )’/> 29     </ROW_SHIPHEADER> 30   </xsl:for-each> 31   <!-- Connection from source node“ROWSET_shipHEADER” to destination node “ROWSET_SHIPHEADER” --> 32  <xsl:value-of select=‘./text( )’/> 33   </ROWSET_SHIPHEADER> 34 </xsl:for-each> 35  <xsl:for-each select=‘shipITEM’> 36   <SHIPITEM> 37   <xsl:for-each select=‘ROWSET_ship1’> 38     <ROWSET_SHIP1> 39     <xsl:for-each select=‘ROW_ship1’> 40       <ROW_SHIP1> 41       <!-- Connection from source node “LineNumber” to destination node“LINENUMBER” --> 42        <LINENUMBER><xsl:value-ofselect=‘LineNumber/text( )’/></LINENUMBER> 43        <!-- Connectionfrom source node “PO_NO” to destination node “ORDERNO” --> 44       <ORDERNO><xsl:value-of select=‘PO_NO/text( )’/></ORDERNO> 45       <!-- Connection from source node “SHP_PRD_NO” to destination node“PARTNO” --> 46        <PARTNO><xsl:value-of select=‘SHP_PRD_NO/text()’/></PARTNO> 47        <!-- Connection from source node “ORD_QTY” todestination node “ORDERQTY” --> 48        <ORDERQTY><xsl:value-ofselect=‘ORD_QTY/text( )’/></ORDERQTY> 49        <!-- Connection fromsource node “REQ_DATE” to destination node “ORDERREQDATE” --> 50       <ORDERREQDATE><xsl:value-of select=‘REQ_DATE/text()’/></ORDERREQDATE> 51        <!-- Connection from source node“SHIP_DATE” to destination node “SHIPDATE” --> 52       <SHIPDATE><xsl:value-of select=‘SHIP_DATE/text( )’/></SHIPDATE>53        <!-- Connection from source node “SHIP_QTY” to destinationnode “WAFERQTY” --> 54        <WAFERQTY><xsl:value-ofselect=‘SHIP_QTY/text( )’/></WAFERQTY> 55        <!-- Connection fromsource node “LAST_DATE” to destination node “INVOICEDATE” --> 56       <INVOICEDATE><xsl:value-of select=‘LAST_DATE/text()’/></INVOICEDATE> 57        <!-- Connection from source node “SO_NO” todestination node “INVOICENO” --> 58        <INVOICENO><xsl:value-ofselect=‘SO_NO/text( )’/></INVOICENO> 59        <!-- Connection fromsource node “REMARK” to destination node “NOTES” --> 60       <NOTES><xsl:value-of select=‘REMARK/text( )’/></NOTES> 61      <!-- Connection from source node “ROW_ship1” to destination node“ROW_SHIP1” --> 62       <xsl:value-of select=‘./text( )’/> 63      </ROW_SHIP1> 64      </xsl:for-each> 65     <!-- Connection fromsource node “ROWSET_ship1” to destination node “ROWSET_SHIP1” --> 66    <xsl:value-of select=‘./text( )’/> 67     </ROWSET_SHIP1> 68   </xsl:for-each> 69    <xsl:for-each select=‘ROWSET_shipMEMOS’> 70    <ROWSET_SHIPMEMOS> 71      <xsl:for-each select=‘ROW_shipMEMOS’> 72      <ROW_SHIPMEMOS> 73        <!-- Connection from source node“MEMONAME” to destination node “MEMONAME” --> 74       <MEMONAME><xsl:value-of select=‘MEMONAME/text( )’/></MEMONAME> 75       <!-- Connection from source node “MEMO” to destination node“MEMO” --> 76        <MEMO><xsl:value-of select=‘MEMO/text( )’/></MEMO>77       <!-- Connection from source node “ROW_shipMEMOS” to destinationnode “ROW_SHIPMEMOS” --> 78       <xsl:value-of select=‘./text( )’/> 79      </ROW_SHIPMEMOS> 80      </xsl:for-each> 81     <!-- Connectionfrom source node “ROWSET_shipMEMOS” to destination node“ROWSET_SHIPMEMOS” --> 82     <xsl:value-of select=‘./text( )’/> 83    </ROWSET_SHIPMEMOS> 84    </xsl:for-each> 85   <!-- Connection fromsource node “shipITEM” to destination node “SHIPITEM” --> 86  <xsl:value-of select=‘./text( )’/> 87   </SHIPITEM> 88 </xsl:for-each> 89 </INSERT> 90 </xsl:template> 91 </xsl:stylesheet>

After the input data has been mapped and stored as raw data as describedabove and in connection with TABLE 2, TABLE 3, TABLE 4 and TABLE 5, themapped raw input data is then processed in the DATA INTEGRITY UNIT 88-6including the Data Checking unit 88-6 ₁ and the Data Cleansing 88-6 ₂ toimprove the quality of the raw data.

One of the significant barriers to efficient supply chain management ispoor data quality. A large amount of the data is provided by suppliersfor Fabless semiconductor buyers. The buyers and suppliers (togetherclients of the supply chain management system) are connected in commonover the Internet and the suppliers supply local supplier information tosaid system via electronic records and reports. A record is a singleentry at one time and reports reflect accumulated data from a number ofrecords or other reports. The data integrity unit of FIG. 11 operates toprocess the raw data to obtain clean processed data. The clean processeddata is checked for consistency with buyer's original local informationas well as the local information provided by all the other suppliers inthe supply chain.

The data integrity processing is divided into five parts:

Part 1. Data Consistency Within a Record.

Part 2. Data Consistency Within a Report.

Part 3. Data Consistency Across Different Reports from a ParticularSupplier.

Part 4. Data Consistency Between Supplier and Buyer Data.

Part 5. Data Consistency Between Suppliers.

In connection with the different parts, the data relates to WIP (Work InProgress) Reports, activity-based Transaction Reports (TR) includingDaily Transaction Reports (DTR), Orders including Purchase Orders (PO)and Work Orders (WO), Shipment Reports and Invoices.

For each of Part 1 to Part 5, cleansing is performed for Static DataConsistency and for Dynamic Data Consistency. By way of example, forStatic Data Consistency, in a PO, the Lot No, and Part No are checkedfor consistency. By way of example, for Dynamic Data Consistency, DateSequence, Quantity Sequence and Routing Sequence are checked.

In connection with Part 1, Data Consistency Within a Record, typicallythe following are checked:

-   -   1. Required Field Missing.    -   2. Date Sequence Check. For example, the sequence ordered        date<=received date<=start date<=completed date<=shipped date is        checked where “<=” means “is earlier than”.    -   3. Quantity Sequence Check. For example, the sequence received        qty≧start qty≧completed qty≧shipped qty is checked where “≧”        means “is greater than or equal to”.    -   4. Date out of Reasonable Range. For example, (current        date-start date) is too large and estimated completion date is        before the current date.    -   5. Quantity out of Reasonable Range. For example, scrap or        downgrade quantity too big.    -   6. Status of a Lot Inconsistent with WIP Quantity.    -   7. Data Dictionary Check. Key data is included and        cross-referenced. For example, device is not found in device        master table, item number is not found in item master table, WIP        status key word is not conformed to the pre-defined        specification. A master dictionary for each type of A data is        stored in the master table to enable checking to be performed.

As an example in connection with Part 2, Data Consistency Within aReport, the following are checked:

-   -   1. Duplicated Data Check. For example, the same lot appears in        more than one record in a WIP or the same transaction appears        twice in a DTR.    -   2. Date Sequence Error. For example, complete-out before        receive-in transaction in DTR.    -   3. Status Sequence Error. For example, status sequence should        be: (scheduled)<(active or hold)<(completed or closed)<(ship or        closed) where “<” means prior to.

As an example in connection with Part 3, Data Consistency AcrossDifferent Reports from a Particular Supplier, the following are checked:

-   -   1. Data Content Inconsistency. For example, device or item has        no changes for the same lot at a different date.    -   2. Quantity Inconsistency. For example, total quantity        (WIP+scrap+warehouse) changes for the same lot on a different        date.    -   3. Date Inconsistency. For example, start date or completion        date changes for the same lot.    -   4. WIP Movement Error. For example, a lot has been completed        then moves back to WIP.    -   5. Status Sequence Error. For example, a lot moves to complete        before becomes active.    -   6. Abnormally Long Cycle Time.    -   7. Abnormally Low Yield.

As an example in connection with Part 4, Data Consistency BetweenSupplier and Buyer's Data, the following are checked:

-   -   1. Date Sequence Error. For example, a downstream supplier        received before the upstream supplier shipped.    -   2. WIP Movement Error. For example, the same lot appears at two        different suppliers at the same time.    -   3. Status Sequence Error    -   4. Abnormal Long Cycle Time    -   5. Shipped but Not Received    -   6. Shipped Quantity Does Not Equal Received Quantity

As an example in connection with Part 5, Data Consistency BetweenSuppliers, the following are checked:

-   -   1. Consistency Between Purchase Order and Work Order. For        example, device and item no should be consistent; sum of work        order cost should be equal or less than the blanket purchase        order amount.    -   2. Consistency Between WIP and Production Order. For example,        Production Order No, Device, Item No, and Qty in WIP should        match with the production order information.    -   3. Consistent Between DTR and Production Order. For example,        production order no, device, item no, and qty in DTR should        match with the production order information.    -   4. Consistency Between WIP and DTR. For example, the difference        in WIP between the two consecutive dates should be equal to        amounts shown in DTR.    -   5. Consistency Between DTR and Shipment Report.    -   6. Consistency Between DTR and Inventory. For example, the        Inventory report should be equal to the results obtained by the        cumulative DTR.

FIG. 12 depicts one example of a multiple supplier branch in a supplychain transaction where after the Wafer Sort stage by supplier testa,the Assembly stage for a lot is distributed to three suppliers, namelypkgk, pkgz and pkgftp.

In FIG. 12, the Raw Material is an input to the Fab stage at supplierfabc and Lot No T0239A is assigned. When the Fab stage work is complete,a Wafer Shipping Notice is issued and the wafers are delivered for theWafer Sort stage to supplier testa for the Lot No T0239A. When the WaferSort stage work is complete, a Sorted Wafer Shipping Notice is issuedand the scribed wafers are delivered for the Assembly stage to Assemblysupplier pkgk with Lot No T0239A-1 assigned, are delivered for theAssembly and Final Test stages to Assembly & Final Test supplier pkgzand Lot No T0239A-2 is assigned, and delivered for the Assembly andFinal Test stages to Assembly & Final Test supplier pkgftp and Lot NoT0239A-3 is assigned. When the Assembly supplier pkgk with Lot NoT0239A-1 completes the packaging, a Assembled Die Shipping Notice isissued and the packaged devices are delivered for the Final Test stageto the Final Test supplier pkgftp with Lot No T0239A-1 retained. Whenthe Final Test supplier pkgftp finishes the Final Test on Lot NoT0239A-1, the Finished Goods are available. When the Final Test supplierpkgz finishes the Final Test on Lot No T0239A-2, the Finished Goods areavailable. When the Final Test supplier pkgftp and finishes the FinalTest on Lot No T0239A-3, the Finished Goods are available.

FIG. 13 depicts cross supplier error checking in the example of FIG. 12.The Wafer Sort stage supplier testa for the Lot No T0239A-2 has an OutDate, indicated by 2* in FIG. 13, of Feb. 28, 2002 where the designatedsupplier is pkgz. The supplier pkgz for the Lot No T0239A-2, however,has an In Date, indicated by 2* in FIG. 13, of Jan. 28, 2002 which ofcourse is an error since the goods could not have been received by pkgzbefore they were shipped by testa. This error is detected by the DATAINTEGRITY UNIT 88-6 of FIG. 11.

In FIG. 13, the Assembly stage supplier pkgk for the Lot No T0239A-1 hasa QTY/die Out quantity, indicated by 1* in FIG. 13, of 3200 where thedesignated supplier is pkgftp. The supplier pkgftp for the Lot NoT0239A-1, however, has a QTY/die In quantity, indicated by 1* in FIG.13, of 4200 which of course is an error since more goods could not havebeen received by pkgftp then were shipped by pkgk. This error isdetected by the DATA INTEGRITY UNIT 88-6 of FIG. 11.

FIG. 14 depicts one example of a lot tracking report. Lot Tracking isexecuted by the BUSINESS LOGIC 98-2 of FIG. 10 to store detailedinformation related to a lot in the production supply chain. Theinformation tracked in the lot tracking has two categorizes as follows:

-   -   Category 1. Static Data: where the data are fixed during the        manufacturing processes.    -   Category 2. Dynamic Data: where the data can be changed during        the manufacturing processes.

The Static Data includes:

a) Lot number,

b) Part no,

c) Purchase order no,

d) Production order no,

e) Date code,

f) Supplier,

g) Routing,

h) Order date,

i) Order Qty,

j) Unit Price,

The Dynamic Data includes two main parts, namely, Date Information andQty Information where they have the following subparts:

a) Date Information:

1) Received date

2) Start date

3) Hold date

4) Completed date

5) Ship date

b) Qty Information

1) Received Qty

2) Returned Qty

3) Start Qty

4) Hold Qty

5) Completed Qty

6) Good part Qty

7) Scrap part Qty

8) Downgrade Qty

9) Ship Qty

Lot tracking records the flow of a lot by keeping its genealogy in orderto track the lot history. These records include a parent-childrelationship for the unsplit lots and include a sibling relationship forsplit lots. Lot tracking information is loaded, for example, using WIPor DTR information. Lot tracking keeps a complete and consistent dataset for all the production and finance related information in onecentral place, that is, in the 97′-2 of FIG. 11. With this commonrepository of lot information for the entire supply chain, performancechecking (such as cycle time and yield analysis) and detailed costreports down to the lot details are provided supply chain managementsystem.

In lot tracking and as shown in the FIG. 14, the supply chain managementsystem assigns a Base Lot indicator number to every lot. In FIG. 14,that Base Lot number is N1805 and a Lot No related to the Base Lotnumber is also kept so that the routing to and local identification foreach of the suppliers is recorded in the lot tracking information. Theparticular Base Lot number N1805 of FIG. 14 has a ROUTE that traces thesequence Fab at supplier fabc with Base Lot number N1805, Wafer Sort atsupplier testa with Base Lot number N1805, Assembly at supplier pkgkwith Lot No N18058 and Final Test at supplier pkgftp with Lot NoN18058.1, with Lot No N18058.2 and with Lot No N18058.3.

FIG. 15 depicts a first cross supplier lot tracking example. In FIG. 15,the Raw Material is an input to the Fab stage at supplier fabc and LotNo N1805 is assigned. When work at the Fab stage is complete, a WaferShipping Notice is issued and the wafers are delivered for the WaferSort supplier testa for the Lot No N1805. When the Wafer Sort stage workis complete, a Sorted Wafer Shipping Notice is issued and the sortedwafers are delivered for the Assembly stage to Assembly supplier pkgkwith Lot No N1805S assigned. When the Assembly supplier pkgk with Lot NoN1805S completes the packaging, an Assembled Die Shipping Notice isissued and the packaged devices are delivered for the Final Test stageto the Final Test supplier pkgftp with Lot No N1805S.1, Lot No N1805S.2and Lot No N1805S.3 assigned. When the Final Test supplier pkgftpfinishes the Final Test on Lot No N1805S.1, Lot No N1805S.2 and Lot NoN1805S.3, the Finished Goods are available for each of those lots.

FIG. 16 depicts a second cross supplier lot tracking example. In FIG.15, the Raw Material is an input to the Fab stage at supplier fabc andLot No T0239A is assigned. When the Fab stage work is complete, a WaferShipping Notice is issued and the wafers are delivered for the WaferSort stage to supplier testa for the Lot No T0239A. When the Wafer Sortstage work is complete, a Sorted Wafer Shipping Notice is issued and thesorted wafers are split into three orders and are delivered for theAssembly stage to Assembly supplier pkgk with Lot No T0239A-1 assigned,are delivered for the Assembly stage to Assembly supplier pkgz with LotNo T0239A-2 assigned and are delivered for the Assembly stage toAssembly supplier pkgftp with Lot No T0239A-3 assigned. When theAssembly supplier pkgk with Lot No N1805S completes the packaging, aAssembled Die Shipping Notice is issued and the packaged devices aredelivered for the Final Test stage to the Final Test supplier pkgftpwith Lot No N1805S.1, Lot No N1805S.2 and Lot No N1805S.3 assigned. Whenthe Final Test supplier pkgftp finishes the Final Test on Lot NoN1805S.1, Lot No N1805S.2 and Lot No N1805S.3, the Finished Goods areavailable for each of those lots.

FIG. 17 depicts an Actual Cost—Lot Detail Report for the Lot NoN18005S.1 from Final Test Supplier pkgftp of FIG. 15. The ability of thesupply chain management system to run the FIG. 15 reports results fromthe Lot Tracking that is performed. In order to perform Lot Tracking,the mapping of fragmented information among multiple Suppliers isrequired. The accuracy of the report depends on the accuracy of theinformation and hence the data integrity processing is important toreport accuracy.

FIG. 18 depicts the purchase order logic flow for creation andacceptance of orders. Such orders are of the type described inconnection with FIG. 5, FIG. 6 and FIG. 7 where a buyer issues a set ofdependent purchase orders in order to progress Raw Materials to FinishedProduct. As a first step, a Buyer will initiate the process Buyer CreateBPO entry at A to create a blanket purchase order. The terms of the BPOare set and may be a standard contract with standard terms andconditions of the Buyer. Normally, the BPO undergoes one or mangerapprovals for the Buyer usually based upon price thresholds for eachmanager. The higher the price, the more management levels that may berequired. No Manager1Approve ? is required if the price is less than afirst threshold, Price≦$T1, and a Yes results sending the BPO to theSupplier input C. If the BPO price is not less than a first threshold,Price≦$T1, and a No results, a Manager1Approve ? is required and if a Noresults, a return is made for further adjustment of the BPO. If aManager1Approve ? is required and is Yes, the approval process continuesfor one or more additional approvals. For example, when noManager2Approve ? is required (the price is less than a secondthreshold, Price≦$T2) and a Yes results sending the BPO to the Supplierinput C. If the BPO price is not less than a second threshold,Price≦$T2, and a No results, a Manager2Approve ? is required and if a Noresults, a return is made for further adjustment of the BPO. If aManager2Approve ? is required and is Yes, the approval process continuesfor one or more additional approvals. Assuming Manager2Approve ? is thelast required and a Yes results sending the BPO to the Supplier input C.

If a BPO exists, or in the absence of a BPO if one is not to be used, aBuyer from time to time will initiate the process Buyer Create POentering at B to create a purchase order. The terms of the PO are setand may be a standard contract with standard terms and conditions underthe BPO of the Buyer or otherwise. As a first step, a Conditions OK?check is made to make sure that conditions are properly established forthe PO. If the current PO is dependent upon the output of another stage,perhaps from a different Supplier, the conditions precedent for the POare checked and if satisfied, a Yes will forward to a Terms OK? checkand if not a No will return to PO for further processing. As a secondstep, a Terms OK? check is made to make sure that terms of the PO arecorrect. For example, if the PO is under a BPO, then a check istypically made to determine if the quantity and cost is within thebalance remaining on the BPO. If the terms for the PO are checked and ifsatisfied, a Yes will forward to a Terms Adjust where, for example, theamount of the current PO will decrement the balance remaining on theBPO. If the Terms OK? check is not satisfactory, a No will return to POfor further processing. Normally, the PO undergoes one manger approvalManager0 Approve? and if a Yes results, the processing is sent to theSupplier input C and if No, process is sent to PO for further processingof the PO

When a Supplier receives a Supplier Accept BPO/PO input, entering at Cto create approval of a Buyer purchase order. The terms of the PO areset and may be a standard contract with standard terms and conditionsunder the BPO of the Buyer or otherwise. As a first step, a BPO TermsOK? check is made to make sure that terms are properly established forthe PO or BPO. If the terms of the BPO are OK, a Yes will forward to aTerms OK? check and if not a No will return to BPO/PO for furtherprocessing. As a second step, a PO Terms OK? check is make to make surethat the terms of the PO are correct and if Yes will forward processingfor manager approval. If the Terms OK? check is not satisfactory, a Nowill return to BPO/PO for further processing. Normally, the PO undergoesone manger approval Manager Approve? and if a Yes results, theprocessing terminates with Order Confirmed.

FIG. 19 depicts an example of Final Test Purchase Order. The PO of FIG.19 is in an on-line form to Supplier pkgftp and includes in the lowerright-hand corner a thumbnail image of an attachment that detailscertain aspects of the PO. The ability of the supply chain managementsystem to run reports of the FIG. 19 type relies upon the Lot Trackingfacility. In order to perform Lot Tracking, the supply chain managementsystem maps fragmented information that inherently is fragmented amongmultiple Suppliers since there is no agreed upon standard in theindustry. As described, the local information for each client (Buyersand Suppliers) is mapped with reference to a master table thatconstitutes a super set of all the local tables for each of the clients.The accuracy of each report depends on the accuracy of the mappedinformation and hence the data integrity processing is important inorder to be able to have reporting accuracy among multiple Suppliers andamong multiple Buyers and multiple Suppliers.

FIG. 20 depicts an example of the attachment that appears as a thumbnailimage in the Final Test Purchase Order of FIG. 19.

FIG. 21 depicts an example of a Wafer Rolling Output Report. The abilityof the supply chain management system to run reports of the FIG. 21 typerelies upon the Lot Tracking facility. In order to perform Lot Tracking,the supply chain management system maps fragmented information thatinherently is fragmented among multiple Suppliers since there is noagreed upon standard in the industry. As described, the localinformation for each client (Buyers and Suppliers) is mapped withreference to a master table that constitutes a super set of all thelocal tables for each of the clients. The accuracy of each reportdepends on the accuracy of the mapped information and hence the dataintegrity processing is important in order to be able to have reportingaccuracy among multiple Suppliers and among multiple Buyers and multipleSuppliers.

FIG. 22 depict an example a Finished Goods Rolling Output Report. Theability of the supply chain management system to run reports of the FIG.22 type relies upon the Lot Tracking facility. In order to perform LotTracking, the supply chain management system maps fragmented informationthat inherently is fragmented among multiple Suppliers since there is noagreed upon standard in the industry. As described, the localinformation for each client (Buyers and Suppliers) is mapped withreference to a master table that constitutes a super set of all thelocal tables for each of the clients. The accuracy of each reportdepends on the accuracy of the mapped information and hence the dataintegrity processing is important in order to be able to have reportingaccuracy among multiple Suppliers and among multiple Buyers and multipleSuppliers.

FIG. 23 depicts an example a Work in Progress Inventory Report. Theability of the supply chain management system to run reports of the FIG.23 type relies upon the Lot Tracking facility. In order to perform LotTracking, the supply chain management system maps fragmented informationthat inherently is fragmented among multiple Suppliers since there is noagreed upon standard in the industry. As described, the localinformation for each client (Buyers and Suppliers) is mapped withreference to a master table that constitutes a super set of all thelocal tables for each of the clients. The accuracy of each reportdepends on the accuracy of the mapped information and hence the dataintegrity processing is important in order to be able to have reportingaccuracy among multiple Suppliers and among multiple Buyers and multipleSuppliers.

In the supply chain management system, an alert process is provided thatextends across the multiple Suppliers environment and the multipleBuyers and multiple Suppliers environment. Typically, a Buyer having anintegrated circuit (IC) design relies upon Production Engineers,Production Control Engineers or other Production Control (PC) personnelto find problems and exceptions that require action or correction duringmanufacture and procurement. Procurement from a manufacturing supplychain having multiple dependent suppliers, that is, where the outputfrom one Supplier is the input for other Suppliers, has increasedcomplexity when compared with less interdependent supply chains. If aBuyer can only use the Finished Product to solve problems, the job istedious and error prone. The alert function is robust and extends to allstages in the supply chain. The alert function as one of the supplychain management functions greatly enhances problem identification andcorrection in the supply chain.

The supply chain management system performs alert processes based uponalert conditions for specific events/reports/process. The alertconditions are selected by clients. Alert reports are accessible toclients through onscreen operations or through other i-commerce methodsof communication. Typically, alert conditions are communicated daily (ormore frequently if desired) from the supply chain management system toclients in the form of event generation and alert messages.

By way of an example for the alert functions, it is assumed for purposesof explanation that for a particular part (PROD), in the process of P,the standard production cycle time is X days. The production control(PC) personnel, or production control (PC) agent if an automatedcomputer system, of a client specifies that if the real cycle time islonger than the standard cycle time by Y days, the client is to bealerted. The supply chain management system implements the algorithm asfollows in TABLE 6:

TABLE 6 Store info by PROD, P, X (static info) Store info by PC, Y(Client dependent) Periodically check the rule (for example, each time aproduction report     enters the supply chain management system) asfollows:   If report has product PROD     If report is for process P      If reported completion time − start time > X         Store thisrecord into Cycle > stdCycleTime         With CycleTime = completiontime − start time         With product = PROD         With process = pWhen client (PC) accesses report,   If client is PC     List anyexisting records in stdCycleTime       Where product = PROD       ANDprocess = p       AND CycleTime > Y.

The implementation of TABLE 6 is suitable for both standard reports andclient preferences for improved performance.

Alerts are divided into categories:

-   -   1) Abnormal time lapse:    -   a. Long Queue-in Time: The Queue-in Time is the period from        receiving material (Received Date) to the start of the        production (Start Date). A Long Queue-in Time is when the        Queue-in Time is longer than a specified period. Usually a Long        Queue-in Time results from a constraint in production capacity        or a delay in paper work.    -   b. Long In-process Time: The In-process Time is the amount of        time in a production process, WIP, and a Long In-process Time is        when the In-process Time is taking an abnormally long time.    -   A Buyer or other client may define a threshold for ‘long cycle        time’ (per routing stage) and the supply chain management system        reports any active WIP beyond the specified threshold as a Long        In-process Time.    -   c. Long On-hold Time: The On-hold Time is time when a production        process, WIP, is put on hold due to a quality issue, a machine        setup problem, a buyer request or other reason. A Buyer or other        client may define a threshold for ‘long hold time’ (per routing        stage) and the supply chain management system reports any active        WIP beyond the specified threshold as a Long On-hold Time.    -   d. Long In-house Warehouse Time: During and after the production        process, WIP, the materials or finished goods are usually put in        the supplier's warehouse for temporary storage. This storage is        called In-house Warehouse Time (also Die/Wafer bank time). A        Long In-house Warehouse Time is when the In-house Warehouse Time        is too long. A Buyer or other client may define a threshold for        ‘long in-house warehouse time’ and the supply chain management        system reports any storage beyond the specified threshold as a        Long In-house Warehouse Time.    -   e. Long In-transit Time: The In-transit Time is the time lapse        between the shipping of one supplier to the receiving of the        following supplier. In-transit goods and materials generally are        the most difficult to track in a supply chain. A Buyer or other        client may define a threshold for ‘in-transit time’ and the        supply chain management system reports any storage beyond the        specified threshold as a Long In-transit Time. The supply chain        management keeps a log of how long it takes from shipping to        receiving at each stage.    -   f. Early Complete Notice—An early warning (x-days before the        estimated completion date) is provided to enable a PC to start        planning the production flow. This feature is important for Fab        and Wafer Sort stages.    -   g. Stationary Lot Report—A log to show lot movement during a        given period.    -   2) Abnormal yield    -   a. Low Yield Threshold is defined by the Buyer or other client.        The supply chain management system tracks yield down to per        device, per part number, per supplier and identifies low yield.    -   b. Excess Yield Threshold. Sometimes, a supplier reports the        output quantity larger than reasonable, such as greater than the        input quantity causing a yield greater than 100%.    -   3) Order and invoice    -   a. Missing PO. When material is set aside for a manufacturing        process, the accompanying PO has to be there for suppliers to        start the work. However, this is not always done. The supply        chain management system generates alerts for PC in these cases.        The trigger can be set in any stage of the production flow: for        example, when the upstream process is completed, or when the        upstream production is shipped, or when the material is        received.    -   b. Cost Approval Delay. When the production process is finished,        the cost needs to be calculated and approved by PCs. If the cost        calculation and approval process has too great a delay, it is        difficult for PC to reconcile this info with the real production        data, since it has been done a long time ago. The supply chain        management system brings the cost calculation and approval        process to alert the PC as soon as a particular process is done,        it can reduce the future dispute and control the production        cost. N    -   c. Cost Deviation. If the unit cost of a particular unit is        larger than a particular percentage of the standard cost for        such unit, the supply chain management system will bring alert        the PC, it can either be due to a low yield, or due to high unit        cost.    -   d. Received but PO Not Issued—Lot received but PO has not been        issued.    -   e. Shipped but PO for next Stage Not Issued—Lot shipped but PO        has not been issued for the following supplier.    -   f. Completed but PO Not Closed—WIP status is completed and PO is        not closed.    -   g. Completed but Invoice Not Approved—WIP status is completed,        invoice is received and waiting for approval.    -   h. Wip Quantity Larger than Ordered Quantity—WIP quantity should        be equal or less than order quantity, this check is particularly        important for foundry PO/WIP reconciliation.    -   4) Performance Index (After the production is done):    -   a. Yield Report—per device, part number, routing and supplier.    -   b. Cycle Time Report—per device, part number, routing and        supplier.

The supply chain management system employs planning based upon upstreamvisibility in the supply chain. Such capabilities are particularlyuseful in outsourcing to suppliers in a semiconductor supply chain. Inthe semiconductor IC-design outsourcing industry, the buyer (IC-designhouse) deals with multiple suppliers that provide various outsourcingfunctions at different supplier stages. The buyer places a separateorder (Purchase Order) with each supplier. Although the Purchase Ordersare separate between a buyer and each supplier, each supplier depends onthe previous supplier (upstream supplier) in the supply chain. In orderto procure a chip as finished goods, a buyer first orders wafers from aFab supplier (foundry); once the work at the Fab supplier is finished,the buyer orders sorting from a Wafer Sort supplier; after the WaferSort work is finished, the buyer orders Assembly from an Assemblysupplier; and finally, the buyer orders Final Test from a Final Testsupplier. The supply chain management system, for example, is able toperform group order generation for groups of dependent suppliers (Fab,Wafer Sort, Assembly and Final Test suppliers) in the supply chain.

At each step of the supply chain, a downstream supplier waits for theprevious upstream supplier to complete (or partially complete) its workbefore commencement of work under a new order can begin. The supplychain management system allows the buyer to create virtual downstreamorders once upstream orders are underway. The supply chain managementsystem uses estimated date (and continuously update as more up to dateinfo is provided with the WIP data), to create virtual (future) ordersfor the downstream suppliers.

Besides providing the buyer with order creation, the supply chainmanagement system also provides the suppliers with up to dateinformation regarding up coming orders. Downstream suppliers can use thesupply chain management system to view the current status of thematerials, which will eventually be arriving and requiring theirservices.

In an example for describing the operation, a buyer has a requirementfor final goods (FG) of amount Q chips on date D. Based upon thisinformation, the supply chain management system operates as in thefollowing TABLE 7:

TABLE 7 Calculate the initial wafer required:   Using Bill of Routing:    FG is made from FT-FG in Final Test with standard yield       Yft,standard cycle time Dft, by supplier Sft,     Thus the date and quantityto start FT is:       Q-FT = Q / Yft       FTD = D − Dft     FT-FG ismade from AS-FG in Assembly with standard yield       Yas, standardcycle time Das, by supplier Sas,     Thus the date and quantity to startAS is:       Q-AS = Q-FT / Yas = Q / Yft / Yas       ASD = FTD − Das = D− Dft − Das     AS-FG is made from WS-FG in Wafer Sort with standardyield       Yws,standard cycle time Dws, by supplier Sws,       Q-WS =Q-AS / Yws = Q / Yft / Yas / Yws       WSD = ASD − Dws = D − Dft − Das −Dws     WS-FG is made from FD-FG in Foundry, with wafer to die ratio      W2D, with standard cycle time Dfd, by supplier Sfd,     Thus thedate and quantity to start FD is:       Q-FD = Q-WS / W2D = Q / Yft /Yas / Yws / W2D       FDD = WSD − Dfd = D − Dft − Das − Dws − Dfd    (for each lot there are 25 wafers)       QL-FD = Q-FD / 25

According to TABLE 6, the supply chain management system will generateorders for each of the suppliers with the proper quantity and requireddate (WS/AS/FT work orders are lot based).

Since the supply chain management system is connected to the supplychain management system Lot Tracking engine, which keeps track on allthe WIP data, the supply chain management system will constantly updatethe Quantity and Date information in each of the subsequent orders.

Once those orders are generated, the buyer will be notified a few days(user specified) before the next order is needed to be submitted to thesupplier. The user can then come to the supply chain management systemand reconfirm the order and submit it. The entire process is automaticand accurate, and greatly increases the productivity of PC personnel ofthe IC-design company.

While the invention has been particularly shown and described withreference to preferred embodiments thereof it will be understood bythose skilled in the art that various changes in form and details may bemade therein without departing from the scope of the invention.

1-45. (canceled)
 46. A method comprising: receiving at a server, localprocessing information from a plurality of suppliers; translating localprocessing information to a standard format; correlating said processinginformation to a finished goods requirement; transmitting to one or moresupplier information systems a portion of a multi-lot productioninformation, said portion responsive to said correlating; generating oneor more purchase orders in response to said correlating; presenting thepurchase orders on a workstation for approval; wherein the correlatingincludes matching processing information from earlier-stage suppliers tolater-stage suppliers and from later-stage suppliers to finished goods,and the work orders direct suppliers to move product through a supplychain.
 47. The method of claim 46 wherein the local productioninformation includes at least one of quantity on hand, units in process,processing time, processing capacity or time to completion.
 48. Themethod of claim 46 wherein the finished good requirement includes atleast one of quantity, delivery date, delivery method or developmentstage.
 49. The method of claim 46 further including: comparinghistorical compliance with work orders, and tailoring the work order inresponse to said comparing.
 50. A system comprising: a first processorreadable storage device having processor readable code embodied on saidfirst storage device, said processor readable code for programming oneor more servers to perform a method comprising: receiving localprocessing information from a plurality of suppliers; translating localprocessing information to a standard format; correlating said processinginformation to a finished goods requirement; transmitting to one or moresupplier information systems a portion of a multi-lot productioninformation, said portion responsive to said correlating; generating oneor more purchase orders in response to said correlating; presenting thepurchase orders on a workstation for approval; wherein the correlatingincludes matching processing information from earlier-stage suppliers tolater-stage suppliers and from later-stage suppliers to finished goods,and the work orders direct suppliers to move product through a supplychain, and a second processor readable storage device coupled to thefirst storage device, said second storage device having processorreadable code embodied on said second storage device, said processorreadable code for programming one or more clients to perform a methodcomprising: transmitting to a server local processing information;receiving from a server one or more work order; presenting on a displaydevice the work order for approval, and adjusting the local processinginformation in response to the work order.
 51. The system of claim 50wherein the local production information includes at least one ofquantity on hand, work in process, processing time, processing capacityor time to completion.
 52. The system of claim 50 wherein the finishedgood requirement includes at least one of quantity, delivery date,delivery method or development stage.
 53. The system of claim 50 whereinthe method encoded on the first storage device also includes: comparinghistorical compliance with work orders, and tailoring the work order inresponse to said comparing.
 54. A method comprising: receiving localprocessing information from a plurality of suppliers, said lotinformation including lot identification information; translating localprocessing information to a standard format; correlating said processinginformation to a finished goods requirement; transmitting to one or moresupplier information systems a portion of a multi-lot productioninformation, said portion responsive to said correlating and responsiveto the lot information; generating one or more purchase orders inresponse to said correlating; wherein the correlating includes matchinglot information from a plurality suppliers, each supplier representingone or more stages in a multi-stage process, and the work orders directsuppliers to move product through a supply chain such that the finalproduct is identified to the lot.
 55. The method of claim 55 wherein thelocal production information includes at least one of quantity on hand,work in process, processing time, processing capacity or time tocompletion.
 56. The method of claim 54 wherein the finished goodrequirement includes at least one of quantity, delivery date, deliverymethod or development stage.
 57. The method of claim 54 furtherincluding: comparing historical compliance with work orders, andtailoring the work order in response to said comparing.